12
FIVE YEAR LIMITED WARRANTY PROGRAM
This limited warranty program is the only one that applies to this product, and it sets forth all the
responsibilities of Vector Manufacturing, regarding this product. There is no other warranty, other than those
described herein.
This Vector Manufacturing product is warranted, to the original purchaser only, to be free of defects in
materials and workmanship for five years from the date of purchase without additional charge. The
warranty does not extend to subsequent purchasers or users. Manufacturer will not be responsible for any
amount of damage in excess of the retail purchase price of the product under any circumstances. Incidental
and consequential damages are specifically excluded from coverage under this warranty.
This product is not intended for commercial use. This warranty does not apply to accessories or damage to
units from misuse or incorrect installation. Misuse includes wiring or connecting to improper polarity power
sources.
RETURN/REPAIR POLICY: Defective products, other than accessories, may be returned postage prepaid to
manufacturer. Any defective product, other than accessories, that is returned to manufacturer within 30 days
of the date of purchase will be replaced free of charge. If such a product is returned more than 30 days
but less than five years from the purchase date, manufacturer will repair the unit or, at its option, replace it
free of charge.
If the unit is repaired, new or reconditioned replacement parts may be used, at manufacturer’s option. A
unit may be replaced with a new or reconditioned unit of the same or comparable design. The repaired or
replaced unit will then be warranted under the terms of the remainder of the warranty period. The customer
is responsible for the shipping charges on all returned items after 30 days. During the warranty period,
manufacturer will be responsible for the return shipping charges.
LIMITATIONS: This warranty does not cover accessories, bulbs, fuses and batteries, defects resulting from
normal wear and tear (including chips, scratches, abrasions, discoloration or fading due to usage or
exposure to sunlight), accidents, damage during shipping to our service facility, alterations, unauthorized
use or repair, neglect, misuse, abuse, failure to follow instructions for care and maintenance, fire, flood and
Acts of God.
If your problem is not covered by this warranty, call Technical Support at (800) 618-5178 for general
repair information and charges, if applicable. You may also contact us through our website at
www.vectormfg.com.
STATE LAW RIGHTS: This warranty gives you specific legal rights. Some states do not allow limitations on
how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages,
so the exclusions or limitations stated herein may not apply. This warranty gives the purchaser specific legal
rights; other rights, which vary from state to state, may apply.
TO REQUEST WARRANTY SERVICE FOR THIS PRODUCT: Contact Technical Support by telephone, fax or
mail (see below). We suggest that you keep the original packaging in case you need to ship the unit. When
returning a product, include your name, address, phone number, dated sales receipt (or copy) and a
description of the reason for return and product serial number. After repairing or replacing the unit, we will
make every effort to return it to you within four weeks.
WARRANTY ACTIVATION: Please complete Warranty Activation Card and mail to Vector Manufacturing.
Enter “VEC1093DBD” as Model and “40/20/10/4 Amp 12 Volt Smart Automatic Battery Charger” as
Product Type. All Vector products must be registered within 30 days of purchase to activate this warranty.
Mail the completed registration form, along with a copy of the original sales receipt to:
ATTN.: CUSTOMER SERVICE
4140 SW 30th Ave., Ft. Lauderdale, FL 33312
• TOLL FREE: (800) 618-5178 • FAX: (954) 584-5556 •
WARRANTY IS NON-TRANSFERABLE AND NON-REFUNDABLE.
BD050205
VEC1093DBD
USER’S MANUAL
& WARRANTY INFORMATION
IMPORTANT SAFETY INFORMATION, SAVE THESE INSTRUCTIONS
TO REDUCE THE RISK OF INJURY, USER MUST READ AND UNDERSTAND
THIS INSTRUCTIONAL MANUAL. THIS MANUAL CONTAINS IMPORTANT
INFORMATION REGARDING THE OPERATION AND WARRANTY OF THIS
PRODUCT. PLEASE RETAIN FOR FUTURE REFERENCE.
www.vectormfg.com
4140 S.W. 30th Ave., Ft. Lauderdale, FL 33312 U.S.
Toll Free: (800) 618-5178
© 2005 VECTOR MANUFACTURING
MADE IN CHINA
Fully Automatic Electronic
Smart Battery Charger
40/20/10/4 Amp Charge Rates
with 110 Amp Engine Start
VEC1093DBD_Manual_050205 5/5/05 6:32 PM Page 12
iiiii
If a properly grounded outlet is not available, a temporary adapter (like the adapter shown in Figure1B)
may be used to connect this plug to a two-pole receptacle. The temporary adapter should be used ONLY
until a properly grounded outlet can be installed by a qualified electrician.
DANGER — Before using an adapter as illustrated, make certain that the center screw
of outlet plate is grounded.
The green-colored rigid ear or tab extending from adapter must be connected to a properly grounded
outlet. MAKE CERTAIN IT IS GROUNDED. If necessary, replace original outlet cover plate screw with a
longer screw that will secure adapter ground tab to outlet cover plate and connect to grounded outlet.
WARNING
NEVER alter AC cord or plug. If it will not fit, have a proper outlet installed by a
qualified electrician. Improper connection may result in an electric shock.
Note: Use of an adapter is not allowed in Canada. If a grounding type receptacle is
not available, do not use this appliance until the proper outlet has been
installed by a qualified electrician.
Preparing to Charge
1. Determine voltage of battery to be charged by referring to the owner's manual.
2. If it is necessary to remove battery from vehicle to charge, or to clean terminals, always remove
grounded terminal from battery first. Make sure all accessories in the vehicle are off, so as not to
cause an arc.
3. Clean battery terminals. Do not allow corrosion to come in contact with eyes.
4. Add distilled water in each cell until battery acid reaches level specified by battery manufacturer.
This helps purge excessive gas from cells. Do not overfill. For a battery without cell caps
(maintenance free), carefully follow manufacturer's charging instructions.
5. Study all battery manufacturer’s specific precautions, such as removing or not removing cell caps
while charging, and recommended rates of charge.
6. Area around battery should be well ventilated while battery is being charged. Gas can be forcefully
blown away by using a piece of cardboard or other nonmetallic material as a fan.
7. Make sure the initial charging rate does not exceed battery manufacturer’s requirement.
Charger Location
1. Locate charger as far away from battery as cables permit.
2. NEVER place charger directly above battery being charged; gases from battery will corrode and
damage charger.
3. NEVER allow battery acid to drip on charger when reading gravity or filling battery.
4. NEVER operate charger in a closed-in area or restrict ventilation in any way.
5. Marine batteries must be removed and charged on shore.
6. Do not set a battery on top of charger.
DC Connection Precautions
1. Connect and disconnect DC output clamps only after removing AC cord from electric outlet.
2. Never allow clamps to touch each other.
3. Attach clamps to battery chassis as indicated in “Battery Installed in Vehicle” steps 5 and 6, and
in “Battery Outside of Vehicle” steps 2, 4 and 5.
Follow these steps when the battery is installed in a vehicle. A spark near the battery
may cause an explosion. To reduce risk of a spark near the battery:
1. Position AC and DC cords to reduce risk of damage by hood, door, or moving engine part.
2. Stay clear of fan blades, belts, pulleys, and other parts that can cause injury to persons.
3. Check polarity of battery posts. POSITIVE (POS, P, +) battery post usually has larger diameter than
NEGATIVE (NEG, N, –) post.
4. Determine which post of battery is grounded (connected) to the chassis. If NEGATIVE post is
grounded to chassis (as in most vehicles), see 5. If POSITIVE post is grounded to the chassis, see 6.
GROUNDING
PIN (A)
GROUNDING
MEANS
METAL SCREW
ADAPTER (B)
Figure
1A
Figure
1B
IMPORTANT SAFETY INSTRUCTIONS
WARNINGS
1. RISK OF EXPLOSIVE GAS MIXTURES — WORKING IN VICINITY OF A LEAD-ACID
BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING
NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE
THAT EACH TIME BEFORE USING YOUR CHARGER, YOU READ THIS MANUAL AND
FOLLOW THE INSTRUCTIONS EXACTLY.
2. To reduce risk of battery explosion, follow these instructions and those published by
the battery manufacturer and manufacturer of any equipment you intend to use in
vicinity of battery. Review cautionary markings on these products and on engine.
3. This equipment employs parts (switches, relays, etc.) that produce arcs or sparks.
Therefore, if used in a garage or enclosed area, the unit MUST be placed not less
than 18 inches above the floor.
Battery Safety
1. Use of an attachment not recommended or sold by the battery charger manufacturer may result in
a risk of fire, electric shock, or injury to persons.
2. To reduce risk of damage to electric plug and cord, pull by plug rather than cord when
disconnecting charger.
3. An extension cord should not be used unless absolutely necessary. Use of an improper extension
cord could result in a risk of fire and electric shock, and will void warranty.
If an extension cord must be used, make sure:
a. that pins on plug of extension cord are the same number, size, and shape as those of plug on
charger;
b. that extension cord is properly wired and in good electrical condition; and
c. that wire size is AWG#10 (10 gauge) for 100 feet and AWG#8 for distances over 100 feet.
4. Do not operate charger with damaged cord or plug — take to a qualified technician for
replacement of the plug or cord immediately.
5. Do not operate charger if it has received a sharp blow, been dropped, or otherwise damaged in
any way; take it to a qualified service technician.
6. Do not disassemble charger; take it to a qualified service technician when service or repair is
required. Incorrect re-assembly may result in a risk of electric shock or fire, and will void warranty.
7. To reduce risk of electric shock, unplug charger from outlet before attempting any maintenance or
cleaning. Turning off controls without unplugging will not reduce this risk.
8. Do not expose charger to rain, snow or use when wet.
Personal Safety
1. Another person should be within range of your voice or close enough to come to your aid when
you work near a lead-acid battery.
2. Fresh water and soap should be nearby in case battery acid contacts skin, clothing, or eyes.
3. Wear complete eye protection and clothing protection. Avoid touching eyes while working with a
battery. Acid, acid particles or corrosion may get into eyes. Immediately flood eye with cold water
(Eye Wash Station) for at least 15 minutes and seek medical attention immediately.
4. If battery acid contacts skin or clothing, wash immediately with soap and water. If redness, pain or
irritation occurs, seek immediate medical attention.
5. NEVER smoke or allow a spark or flame in vicinity of battery or engine.
6. Be extra cautious to reduce the risk of dropping a metal tool onto battery. This might cause sparks
or short-circuit the battery or other electrical part, which can cause an explosion.
7. Remove personal metal items such as rings, bracelets, necklaces and watches when working with
a lead-acid battery. A lead-acid battery can produce a short-circuit current high enough to cause a
severe burn.
8. Use charger for charging a LEAD-ACID battery only. It is not intended to supply power to a low-
voltage electrical system other than in a starter-motor application. Do not use the battery charger
for charging dry-cell batteries that are commonly used with home appliances. These batteries may
burst and cause injury to persons and damage property.
9. NEVER ATTEMPT TO CHARGE A FROZEN BATTERY.
Power Cord Safety
Charger should be grounded to reduce risk of electric shock. Charger is equipped with an AC cord having
equipment-grounding conductor and a grounding plug. The plug must be plugged into a properly installed
and grounded 110/120 volt AC outlet in accordance with all local codes and ordinances (see Figure 1A).
VEC1093DBD_Manual_050205 5/5/05 6:32 PM Page ii
1
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Charge Rate Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Automatic Float Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Equalizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Recondition Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Alternator Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Approximate Charging Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INTRODUCTION
Thank you for selecting the
40/20/10/4 Amp Smart Battery Charger.
With
proper care and use, it will give you years of dependable service. This battery
charger has a high charge rate of up to 40 amps, a low charge rate of 4 amps and
110 amps of engine starting power. It is designed for charging only
12 volt lead-acid batteries — conventional automotive, maintenance-free, marine
deep cycle and gel — used in cars, trucks, farm equipment, boats, RVs and SUVs,
lawn mowers/garden tractors, motorcycles, personal watercraft, snowmobiles, ATVs
and various applications.
Smart Battery Chargers feature 3-stage high-efficiency charging technology built-in
microprocessor control that ensures fast, safe and complete charging of serviceable
batteries.
Charge Curve
Stage One —
Rapid Start Charge at 40 amps delivers maximum charging
amperage to “wake up” any serviceable 12 volt battery and allows for quick engine
starting in just 1 minute (based on a midsize vehicle battery at 50% charge level).
When battery reaches a maximum safe predetermined voltage, the charger will
automatically signal a "beep" and move into Stage 2 of the charging process.
BEEP
BEEP
OFF BEEP
STAGE THREE
CHARGING
COMPLETE
STAGE ONE
STAGE TWO
iv
5. For negative-grounded vehicle, connect POSITIVE (RED) clamp from battery charger to POSITIVE
(POS, P, +) ungrounded post of battery. Connect NEGATIVE (BLACK) clamp to vehicle chassis or
engine block away from battery. Do not connect clip to carburetor, fuel lines, or sheet-metal body
parts. Connect to heavy gauge metal part of the frame or engine block.
6. For positive-grounded vehicle, connect NEGATIVE (BLACK) clamp from battery charger to
NEGATIVE (NEG, N, –) ungrounded post of battery. Connect POSITIVE (RED) clamp to vehicle
chassis or engine block away from battery. Do not connect clip to carburetor, fuel lines or sheet-
metal body parts. Connect to a heavy gauge metal part of the frame or engine block.
7. When disconnecting charger, disconnect AC cord, remove clamp from vehicle chassis, and then
remove clamp from battery terminal.
8. Do not charge the battery while the engine is operating.
9. See operating instructions for length of charge information.
Follow these steps when the battery has been removed from a vehicle. A spark near
the battery may cause an explosion. To reduce risk of a spark near the battery:
1. Check polarity of battery posts. The POSITIVE post (marked POS,P, +) usually has a larger diameter
than the NEGATIVE battery post (marked NEG, N, –).
2. Attach a 24-inch (minimum length) 6 AWG insulated battery cable to the NEGATIVE battery post
(marked NEG, N, –).
3. Connect the POSITIVE (RED) battery clamp to the POSITIVE battery post (marked POS, P, + or red).
4. Stand as far back from the battery as possible, and do not face battery when making final
connection.
5. Carefully connect the NEGATIVE (BLACK) charger clamp to the free end of the battery cable
connected to the NEGATIVE terminal.
6. Set the charge rate to appropriate setting according to battery size.
7. When disconnecting charger, always do so in reverse sequence of connecting procedure and break
first connection while as far away from battery as practical.
Note: A marine (boat) battery must be removed and charged on shore. To charge it
on board requires equipment specially designed for marine use. This unit is
NOT designed for such use.
SA
VE THESE INSTRUCTIONS
This device complies with part 15 of the FCC rules. Operation is subject to the following two
conditions: (1) this device may not cause harmful interference, and (2) this device must accept
any interference received, including interference that may cause undesired operation.
This equipment has been tested and found to comply with the limits for a Class B digital device,
pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection
against harmful interference in a residential installation. This equipment generates, uses and can
radiate radio frequency energy and, if not installed and used in accordance with the
instructions, may cause harmful interference to radio communications. However, there is no
guarantee that interference will not occur in a particular installation. If equipment does cause
harmful interference to radio or television reception, which can be determined by turning the
equipment off and on, the user is encouraged to try to correct the interference by one or more
of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the receiver is
connected.
• Consult the dealer or an experienced radio/TV technician for help.
VEC1093DBD_Manual_050205 5/5/05 6:32 PM Page iv
3
Controls and Indicators
FUNCTION BUTTONS (FROM LEFT TO RIGHT):
Battery Type (Step 1) — allows the user to select Wet, Gel or AGM type of battery
for efficient and safe charge. Most automotive batteries are Wet batteries. Refer to the
battery manufacturer’s specifications for battery type.
4/10/20/40 AMP (Charge Rate Selector) (Step 2) — allows the user to select
the charge rate based on battery size. This selection and the actual battery charge
rate are monitored by the microprocessor. The charger will stop charging if the rate
is too fast or too slow for the battery size or condition.
110 AMP Engine Start — places the charger in an engine start sequence. This
button will not be activated unless the charger is in the 40 amp charge mode; set the
4/10/20/40 AMP button to 40 amps first to activate this button.
Battery Recond. — is an automatic mode that, once started, continues for 24 hours
and then stops. A series of electrical pulses breaks the crystalline form of lead sulfate
to return these chemicals into useful battery electrolytes. More than 24 hours may be
needed to restore. Periodic reconditioning is recommended to maintain a battery's
optimum performance. However, if 5 cycles does not improve battery performance,
discontinue and recycle the battery.
Battery Voltage (Alternator Voltage Check) — is a quick check that measures
the battery voltage. This check is repeated at various electrical load levels and the
tests allow the user to determine if the alternator can keep up with the loads.
CONTROL PANEL
DIGITAL READOUT
CIRCULATING PATTERN
2
Stage Two —
Absorption Charge maintains the maximum possible charge at a
constant, safe, predetermined voltage. During this phase, the charging voltage remains
constant, while the actual charging current is reduced to allow for the maximum proper
internal chemical energy transfer. At the end of Stage 2, the charger will automatically
move into Stage 3 charge mode.
Stage Three —
Top-Off Charge — voltage is automatically maintained and
reduced to a predetermined level while current is adjusted for a safe, effective battery
charge. At the conclusion of Stage 3, the unit will BEEP signaling the completion of
the charging cycle.
The Automatic Float Charge feature is ideal for maintaining a battery. It automatically
tops off battery as needed to keep battery fully charged all the time.
FEATURES
• This unit has four charge rate settings, accessed by the 4/10/20/40 AMP button:
a) 4 amps: smaller batteries, as in lawn mowers, snowmobiles, motorcycles, etc.
b) 10 amps: mid-sized batteries, as in small cars
c) 20 amps: automobiles and light trucks
d) 40 amps: large truck batteries, banks of RV batteries
• 110 amp engine start
• Automatic Temperature Compensation
• Battery type selection
• Digital diagnostics
• Alternator voltage and battery voltage check
• Digital display shows charge rate, operating mode, fault codes and FUL when
charged
• 1-minute engine start
• 3-stage high-frequency switch mode automatic rapid charging
• Spark resistant reverse polarity and short circuit protection for user
• Built-in battery reconditioning (desulfate)
• Lightweight, high-efficiency design
• Internal short circuit protection
• Cables and clamps self-stored
• Reverse polarity indication
• Microprocessor control (Digital Smart Control) high frequency power
• Compensates for low AC from extension cord use
• Equalization function
• Battery recondition function
VEC1093DBD_Manual_050205 5/5/05 6:32 PM Page 2
5
OPERATING INSTRUCTIONS
Ensure that all installation and operating instructions and safety
precautions are understood and carefully followed by anyone
installing or using the charger. Follow the steps outlined in “Important
Safety Instructions” at the front of this manual.
Charge Rate Selection
After charger clamps are correctly connected, plug in the charger to a 120 volt AC
outlet and the charger will show a circulating pattern on the Digital Display, indicating
power has been applied. Select the proper charge current rate based on battery size.
Press the 4/10/20/40 AMP button and the charger will begin charging at 4 amps.
Pressing the 4/10/20/40 AMP button again will advance the charge rate to 10
amps, again to 20 amps, and again to 40 amps. Pressing the switch again will turn
OFF the charger output and the display will show “000.”
Note: The only time the selected charge rate does not display at the full selected rate
is when the battery is nearly full and charging at either step two or three. The
display will be showing a reduced charge rate. To return to 2A, press the
2/20/40 AMP button. When the battery is fully charged, the charging complete
and “FUL” is displayed on the Digital Display.
WARNING
If Digital Display shows “F02”, the connection to the battery terminals
is bad. Follow the steps outlined in “Important Safety Instructions”
at the front of this manual to disconnect, clean battery terminals,
then reconnect.
If Digital Display shows “F06”, the Red (POSITIVE) and Black
(NEGATIVE) clamps are incorrectly connected to battery terminals.
Follow the steps outlined in “Important Safety Instructions” at the
front of this manual to disconnect, then reconnect in correct polarity.
Charging the Battery
1. Press Battery Type selector until desired battery type LED lights.
Note: The default selection is “GEL” type battery.
2. Press 4/10/20/40 AMP button to begin charging at the 4 amp rate; the unit
sounds a beep and the charging current LED lights. The charger starts charging
at 4 amp rate automatically if 4/10/20/40 AMP button is not pressed within 3
minutes after applying AC power.
If the Display on the charger varies between “F03” and the amp rate, the battery
is sulfated and the charger is trying to give it some charge. If after approximately
2 hours the display just shows “F03”, then the battery will not charge.
Charger occasionally sounds a beep and displays “0.0” during self-test or
charging stage changes.
3. Pressing the 4/10/20/40 AMP button again advances charging rate to 10
amps, pressing once more advances charging rate to 20 amps, and again to 40
amps. (Pressing the button again will turn OFF the charger output and the Display
will show “000”.) This selection and actual battery charge rate are monitored by
the microprocessor, and the unit will stop charging if the selected rate is too fast
or too slow for battery size or condition.
As the battery nears full charge capacity, the unit’s output will automatically drop
to a lower charge rate.
4
INDICATOR:
Large (.375”) 3-Character Digital Display in the upper left of the control panel
indicates the various conditions and/or status codes:
Status Codes
are described in the following chart and on the back of charger.
CONTROL PANEL LED INDICATORS:
WET — lights when battery type selector is on WET battery type
GEL — lights when battery type selector is on GEL battery type
AGM — lights when battery type selector is on AGM battery type.
Float Charge — lights when automatic charge monitoring is active. This feature
allows a battery to maintain its charge over long periods of non-use. If there is any
loss of power to the charger once power is restored charger will automatically return
to the default settings. Battery selector type would be “GEL”.
Battery Voltage — lights when battery voltage is displayed.
Alternator Good — lights when load or not load checks show the alternator is
keeping up with the electrical load.
BUTTON (TO THE RIGHT OF LEDS):
Equalize — a recessed button used to start the equalization process.
AC POWER INDICATOR - When connected to an AC outlet, digital display shows circulating pattern to
indicate power is on. Disconnect charger after use.
FAULT CODES
OPERATION CODES
F01
F02
F03
F04
F05
F06
F07
000
FUL
INTERNAL SHORTED CELL BATTERY - Cannot be charged. Have battery checked by certified auto service center.
EXCESSIVE LOAD ON BATTERY WHILE CHARGING - Check load.
BAD BATTERY CONNECTION - Check battery connection.
BATTERY VOLTAGE TOO LOW TO ACCEPT CHARGE - Have battery checked by certified auto service center.
BATTERY RECONDITIONING - (The letters DES will display for the first 3 seconds.)
INTERNAL OPEN CELL - Have battery checked by certified auto service center.
SULFATED CONDITION - Battery needs to be reconditioned. See manual.
OVERHEATED CONDITION - Disconnect charger and allow to cool for 30 min., check for ample ventilation.
REVERSE POLARITY
ALTERNATOR OUTPUT IS OUT OF TYPICAL OPERATION RANGE
ALTERNATOR VOLTAGE CHECK
CHARGER STANDBY
BATTERY FULLY CHARGED
OVERTIME CONDITION - Battery will not accept a charge after 18 hours of continuous charging. Battery may have
internal damage. Have battery checked by certified auto center.
BATTERY CHARGE RATE IS SET TOO LOW - Set charger to higher charge rate. See manual.
VEC1093DBD_Manual_050205 5/5/05 6:32 PM Page 4
7
6. Fill the battery with distilled water according to the manufacturer’s instructions.
Since batteries may rapidly bubble while being charged, remember to refill (only
with distilled water) after the equalization process is complete and the voltage is
back to normal.
7. Follow the steps in the “Charging the Battery” section on page 5 of this manual.
8. Push the Battery Type Selector Switch until “WET” is displayed. (This mode will
only work if a WET battery is selected.)
9. Choose the correct charge rate and start charging. You can check the battery
voltage by pushing the Battery Voltage button. This will trigger the Battery Voltage
indicator button.
10. Push the Equalize button at any time and the battery will automatically begin to
equalize in 4 amp limited current. Note that in order to push the recessed button
you will need a small pin or ballpoint pen.
11. Every hour, the temperature should be checked by touching the battery. If the
battery is hot to the touch, stop the charging and allow the battery to cool.
12. The voltage rises, but does not go over 15.3v to 16.2v (2.55-2.7v per cell)
depending on ambient temperature; it will automatically adjust.
13. The “WET” LED flashes while the charger is in equalize mode.
14. The digital readout will show “FUL” when the equalization process is complete.
Engine Start
The Engine Start function can supply 110 amps for engine starting.
1. Set the 4/10/20/40 AMP button to 40 amp mode and immediately press the
110A button switch to activate the Engine Start mode.
2. The digital display will countdown from “999” to “000.”
3. When the “000” count is reached and begins flashing on the Display, the vehicle
is ready to start.
4. Crank the engine using manufacturer’s guidelines, typically in 3 to 5 second
bursts. The high current engine starting function requires a resting/cooling period
between tries. The charger will switch back to regular charge mode after
5 seconds and will not allow operation in this mode for 4 minutes. Wait 4 to 5
minutes before a second attempt at starting the engine, if needed.
5. During the rest period, the battery is charging at 40 amps. After engine starts,
follow the steps outlined in “Important Safety Instructions” at the front of this
manual to disconnect.
Recondition Mode
Whenever a lead-acid battery begins to discharge, lead sulfate, an insulator, begins
to build up on the battery’s internal plates. This reduces the ability of the battery to
hold a full charge. When that battery has an immediate charge, most of the lead
sulfate is dissolved and the plates are free of this insulation. If a battery remains in a
discharged condition over a longer period of time, the lead sulfate changes to a hard
crystalline form, making a full charge difficult to achieve. Reconditioning may “save”
a sulfated battery.
6
Pressing the 4/10/20/40 AMP button repeatedly advances to standby mode;
the unit sounds a beep, displays “000” and stops charging.
4. The battery charger displays the charge current. To view the battery voltage,
press BATTERY VOLTAGE button. The charger will sound a beep and display the
battery voltage for 3 seconds, then returns to displaying the charge current.
5. The display shows “FUL” when the battery is fully charged.
6. Follow the steps outlined in “Important Safety Instructions” at the front of this
manual to disconnect.
Automatic Float Charging
Automatic Float Charging is ideal for maintaining a fully charged battery.
1. Keep the AC power and battery connected after battery is fully charged.
2. The charger monitors the battery and tops it off as needed.
3. The Float Charge indicator lights; the display shows charge current when topping
off the battery and returns to “FUL” when completed.
4. To view battery voltage, press the Battery Voltage button.
Note: Charging can be terminated by pressing the charge rate selector button at any
time when unit is charging. After AC power interruption, charging restarts at 4
amp rate automatically and the battery type will default to “GEL”.
WARNING
If battery size is not known, charge at the 4 amp rate. DO NOT
overcharge batteries.
Equalizing
Equalizing is the process by which the fluid in each of a battery’s cells is equalized.
This process occurs after charging is complete.
WARNINGS
• NEVER TRY TO EQUALIZE A GEL OR AGM CELL. THE RESULTING
EXPLOSION COULD CAUSE PROPERTY DAMAGE, SERIOUS INJURY
AND/OR DEATH.
• Remove or disconnect the vehicle’s battery when equalizing.
The frequency which the equalization process needs to be run depends on the use of
the battery. The more the battery is used, the more undercharged it becomes; thus the
more frequently the battery should be equalized.
1. Do not use this mode on sealed or valve regulated batteries. This mode is only
meant for wet (unsealed/vented) batteries.
2. Make sure there are no flammable sources near the recharging sight.
3. Wear safety glasses, gloves and protective clothing.
4. Remove battery from vehicle. MAKE SURE THAT THE BATTERY HAS GOOD
VENTILATION. The process causes the release of hydrogen and oxygen. An
accumulation of these gases presents a real danger of explosion.
5. Open the battery cap, if removable.
VEC1093DBD_Manual_050205 5/5/05 6:32 PM Page 6
9
APPROXIMATE CHARGING TIMES
The
4/10/20/40 Amp 12 Volt Smart Battery Charger
will automatically
adjust the charge rate as the battery becomes charged and stop when the battery is
fully charged. Deep cycle batteries may require longer charging time.
For estimates of the time it takes to charge a battery, refer to the following table.
Percent of charge
in battery 75% 50% 25% 0%
at 4 Amp rate 3.5 HRS 7 HRS 10.5 HRS 14 HRS
at 10 amp rate 1.4 HRS 2.8 HRS 4.2 HRS 5.5 HRS
at 20 Amp rate 1 HR 1.5 HRS 2.1 HRS 2.8 HRS
at 40 Amp rate 1 HR* 1 HR* 1 HR* 1-2 HRS*
* Not recommended for charging batteries less than 80 Ah
The times shown in the table above are approximate and refer to a 50 Ah automotive
battery. For example, a 50 Ah (12 volt) battery is discharged (50%). How long
should it be charged at the 10 amp rate? See the chart above under “50%” and “at
10 amp rate.”
In most cases, battery charging times will vary depending on the size, age and
condition of the battery. Smaller batteries should be charged at a lower rate (4 amps)
and an extra hour added to charge time.
CARE AND MAINTENANCE
With proper care and minimal maintenance, the
4/10/20/40 Amp 12 Volt
Smart Battery Charger
will provide years of dependable service. For maximum
performance, manufacturer recommends:
• After each use, clean the battery charger clamps — be sure to remove any battery
fluid that will cause corrosion of the clamps.
• Clean the outside case of the charger with a soft cloth and, if necessary, mild soap
solution.
• Do not allow liquid to enter the charger. Do not operate when charger is wet.
• Keep the charger cords loosely coiled during storage to prevent damage to the
cords.
WARNINGS
• Do not use charger if cords or clamps have been damaged in any
way — call Technical Support toll-free at (800) 618-5178.
• There are no user-serviceable parts in this unit.
• Do not open the unit. In the event of malfunction, it must be returned
to manufacturer for professional testing and repair. OPENING THE
UNIT WILL VOID THE MANUFACTURER’S WARRANTY.
8
BATTERY RECONDITION MODE should only be used with 10 Amp Hour (Ah) or
larger capacity lead-acid batteries. Charge the battery to be treated for 20 minutes,
before using RECONDITION Mode. Observe the Digital Display for any codes. This
initial charge will check the battery for shorted cells (F01), open cells (F03) or battery
too low to accept a charge (F02), and to ensure the battery can take a charge. If
code (F03) is displayed, change to the BATTERY RECONDITION MODE.
Remove or disconnect the vehicle’s battery when reconditioning.
1. Make sure the charger is in initiation state with a circulating pattern on the
display or in charge OFF mode with “000” on the display. If not, press
4/10/20/40 AMP button repeatedly until “000” shows on the display.
2. Press the Battery Recondition button to start the process.
3. DES appears on the display for 3 seconds, then it changes to three horizontal
moving bars.
4. The process takes 24 hours and stops automatically. The display shows “000”
when complete.
Alternator Voltage Check
Part 1
No Load (Turn OFF all vehicle’s accessories): The battery must be fully charged
before testing the alternator. Run the engine long enough to achieve
normal idle speed and verify there is a no-load voltage.
1. Press Alternator Check to start the check.
2. Alternator Good LED will light to indicate the alternator is good, or F07
will display if alternator output voltage is out of typical operation range.
3. Press Alternator Check again to stop the test.
Part 2
Under Load (Accessories ON): Next, load the alternator by turning on as many
accessories as possible (except for A/C and DEFROST)
1. Press Alternator Check to start the check.
2. Alternator Good LED will light to indicate the alternator is good, or F07
will display if alternator output voltage is out of typical operation range.
3. Press Alternator Check again to stop the test.
If the first alternator check indicates a good alternator and the second indicates the
alternator is bad, the problem could stem from: loose fan belts, an intermittent diode
failure or possibly bad connections between the battery and alternator and/or ground.
Notes: BATTERY VOLTAGE button is disabled in Alternator Check mode.
F07 may display because someone has added a number of accessory loads
on the charging system, thereby increasing current demand from the
alternator. MAKE SURE THAT THE ALTERNATOR IS RATED TO SUPPORT THE
APPLICATION.
This check may not be accurate for every make, manufacturer and model of
vehicle.
Check only 12 volt systems.
VEC1093DBD_Manual_050205 5/5/05 6:32 PM Page 8
1110
TROUBLESHOOTING
Display Indications/Common Problems/Possible Solutions
No Functions
• Check and make sure the charger is plugged into a live 110/120 volt AC outlet.
• Follow the steps outlined in the Operating Instructions section.
F01 — Internal Shorted Cell Battery
If the battery being charged has an internal shorted cell, the F01 will show. We
recommend taking your battery to a certified automotive service center for evaluation.
F02 — Bad Battery Connection or Battery Voltage Too Low to Accept
Charge
When F02 appears, the most common cause is poor connection to battery.
• Follow the steps outlined in “Important Safety Instructions” at the front of this manual
to disconnect AC cord and clamps, clean battery terminal and reconnect.
• If the situation persists, we recommend taking your battery to a certified automotive
service center for evaluation.
F03 — Sulfate or Unchargeable Battery
Appears when the battery is highly sulfated and cannot accept normal charge current.
• Follow the steps in “Recondition Mode” to recondition the battery.
• Follow the steps in “Equalizing” to equalize the battery.
• If the situation persists after reconditioning and equalizing, we recommend taking
your battery to a certified automotive service center for evaluation.
F04 — Overtime Condition
Appears when charging time exceeds 18 hours. You may be using a charge current
rate too low for a large battery. Select higher charge rate to charge the battery.
F05 — Overheated Condition
The ventilation grill that prevents the air from flowing in and out of the charger may
be blocked.
• Follow the steps outlined in “Important Safety Instructions” at the front of this manual to
disconnect AC cord and clamps, allow the unit to cool for 30 minutes and reconnect.
• Make sure there is ample ventilation before resuming operation.
F06 — Reverse Polarity
The connections to the battery’s POSITIVE and NEGATIVE terminals are incorrect.
Follow the steps outlined in “Important Safety Instructions” at the front of this manual
to disconnect AC cord and clamps and reconnect to battery with correct polarity.
F07 — Alternator Voltage
Alternator output voltage is out of typical operation range.
Charging a Very Cold Battery
If the battery to be charged is very cold (in temperatures below freezing — 0°C/ 32°F),
it cannot accept a high rate of charge. The initial charge rate will be low. The charge
rate will increase as the battery warms. Never attempt to charge a frozen battery.
VEC1093DBD_Manual_050205 5/5/05 6:32 PM Page 10
/
